Wood product and the method and apparatus for making the same



T. R DRAKE WOOD PRODUCT AND THE METHOD ANI.) APPARATUS FOR MAKING THE SAME Filed April 9, 1965 INVENTOR. TficociO/" R United States Patent 3,316,948 WOOD PRODUCT AND THE METHOD AND APPARATUS FOR MAKING THE SAME Theodore R. Drake, 1780 Crestview Ave., Seal Beach, Calif. 90740 Filed Apr. 9, 1965, Ser. No. 446,856 4 Claims. (Cl. 144-318) This invention has to do with a novel wood product and the method and apparatus for making the same.

Throughout the world and in the woodworking arts, there are great quantities of short pieces of lumber, which are established as a result of cutting and/or trimming large pieces of lumber. For example, there are many short unusable pieces of 2 x 4, 4 x 4 and 2 x 6 which are cut off long pieces of lumber, at millsites and the like, to establish lumber of standard length.

It is commonly accepted that short pieces of lumber such as referred to above are of no value and are too costly to handle and do anything with. Accordingly, these materials are considered waste, and are disposed of in as economical a manner as is possible.

It is well known and clearly established that the end grain of wood has many desirable features and/or characteristics. For example, wood flooring have upwardly disposed and exposed end grain has superior wearing characteristics than similar flooring where the grain of the wood is horizontally disposed. Further, wood panels or panel cores and the like made of pieces of wood with end grain disposed outwardly from the plane of the panels are substantially fireproof and afford materially greater sound and heat insulating qualities than similar wood panels and cores wherein the grain of the wood extends parallel with the plane of the panels and/or cores.

Still further, the end grain of wood is highly effective from an esthetic or ornamental standpoint and if it were wood so as to utilize the esthetic effect of the end thereof, it would manner.

grain more likely 'be widely used in such a up the desired structure.

Attempts have been grain blocks together in to provide an elongate made to glue a plurality of end side by side relationship in order cross grain timber or piece of sca bbing the blocks together as by means of nails or by drilling holes through the blocks and stringing them on doll pins and the like. These attempts have also failed due to the fragile, easy to check, crack and split nature of short blocks of wood.

Still other attempts have included taping a plurality of blocks together with strips of paper along their opposite sides, where the edge grain of the wood is exposed.

3,316,943 Patented May 2, 1967 This latter method has proved undesirable since the tapes become an integral, exposed or visible part of the product and the structure which the product is used to establish and is ineffective in that the tapes are not sufficiently strong and are too readily torn or otherwise parted when the product is flexed to the slightest extent. Further, such tapes can only be effectively secured to the side graln surfaces of the assembled row of blocks. Such tapes cannot be advantageously glued to the extremely porous, fibrous and relatively irregular or rough end grain surface of such blocks of wood.

An object of my invention is to provide an elongate fabricated board or timber of wooden blocks, the grain of which extends transverse the longitudinal axis of the product.

Another object of this invention is to provide a prod not of the character referred to which is sufliciently strong and rigid so that it can be easily and conveniently handled and used without breaking and/ or separating.

It is an object of my invention to provide a product of the character referred to which is made up of short ends and pieces of standard sizes of lumber which were heretofore considered waste.

A further object of this invention is to provide, arrange and assemble small pieces of wood together in an easy and convenient to handle and use form wherein the end grain can be advantageously exposed and put to use and service.

A feature of my invention is to provide a plurality of wood blocks in an elongate row or series, in side by side relationship, to establish longitudinal grooves in the longitudinal sides of the assembled row of blocks and to insert and fix an elongate tie cord in each groove to secure the blocks in tight assembled relationship.

It is a further object of the present invention to provide a novel method and apparatus for establishing my new product.

The various objects and features of my invention will be fully understood from the following detailed description of a typical preferred form and carrying out of my throughout which description reference is made to the accompanying drawing, in which:

FIGURE 1 is an isometric view of my new product;

FIGURE 1A is an isometric view of another form of my new product;

FIGURE 2 is a side elevational view of the apparatus provided to carry out my new process for making my new product;

FIGURE 3 is a plane elevational view of the apparatus shown in FIGURE 2;

FIGURE 4 is a view taken substantially as indicated by line 4-4 on FIGURE 2;

FIGURE 5 is a view taken substantially as indicated by line 5- 5 on FIGURE 2;

FIGURE 6 is a view taken substantially as indicated by line 6-6 on FIGURE 2;

FIGURE 7 is a view taken substantially as indicated by line 7-7 on FIGURE 2, and;

FIGURE 8 is a view taken substantially as indicated by line 88 on FIGURE 2.

The product P that I provide which is illustrated in FIGURE 1 of the drawings includes, an elongate row of elongate wood blocks B, rectangular in cross section and having flat top and bottom surfaces 10 and 11, fiat side surfaces 12 and flat ends 12. The grain of the wood extends longitudinally of the blocks B and is exposed at the opposite ends 13 thereof. The blocks. B are arranged in tight side by side relationship, with their tops, bottoms and ends in common planes.

The elongate assembly of blocks B has or defines longitudinally extending top and bottom surfaces X and Y defined by the top and bottom surfaces It) and 11 of the blocks, fiat longitudinally extending side surfaces Z 3 iefined by the ends 13 of the blocks and ends E defined :y the exposed side 12 of the first and the last block of :he assembly.

The assembly is provided with an elongate longitudinally extending, laterally outwardly opening channel or groove G in each side surface Z, intermediate the top and bottom edges of said surfaces and an elongate cord C engaged and fixed in each groove G to extend between and to secure each adjacent block of the assembly, together.

The cords C are preferably press fitted into the related grooves G, are tensioned and are cemented or glued in the grooves, whereby the cords hold the blocks in tight assembled relationship and establish an integral part of the assembly and of each block going to make up the assembly. The product P illustrated in FIGURE 1A of the drawing is the same as that illustrated in FIGURE 1 of the drawing and described above, except that the grain of the wood extends vertically, between the top and bottom surfaces and 11 of the blocks B and is exposed at the top and bottom surfaces X and Y of the assembly, rather than at the sides Z thereof.

In all other respects, the two forms, P and P of the product, are identical.

It will be apparent that the product provided by the present invention provides what is, in effect, elongate fabricated boards having laterally disposed end grain throughout their longitudinal extent.

It will also be apparent that the plurality of wood blocks going to make up my new product are effectively held and maintained in assembled relationship by the cords C.

Further the cords C serve to hold each block together and to prevent the blocks from splitting and parting.

It will be apparent that the product effectively utilizes small blocks of wood, which ordinarily would be considered as scrap, and places such blocks of wood in a condition or form where they can be effectively and economically employed and put to use.

In the preferred carrying out of the invention, the cords C are established of hemp, twisted Kraft paper or other vegetable fiber or vegetable fiber product which is strong and durable, but which is such that it can be advantageously cut and worked with ordinary woodworking tools and is not such as might interfere or prevent working on or with the product with ordinary woodworking tools and the like.

The process employed to manufacture my new product includes arranging a plurality of blocks B in side by side relationship, with the grain of each block extending transverse the longitudinal axis of the assembly and parallel with the grain of each adjacent block, next, cutting the longitudinal grooves G in the side surfaces Z of the assembly of blocks; next, depositing glue or a suitable cement in the grooves G; then, arranging the cords C in the grooves, under tension, and in the glue or cement; and finally, drying and curing the glue.

In the preferred carrying out of my process, a continuous row of blocks B is established and advanced longitudinally. The grooves G are progressively and continuously cut and established in the opposite side surfaces Z of the assembled row of blocks, as said row of blocks is advanced longitudinally. The glue or cement is deposited continuously in the grooves G, following their establishment and as the row of blocks is advanced longitudinally. The cords C have their ends secured and fixed to the first or leading block of the row or series of blocks and are drawn taut and are progressively urged into engagement in the grooves and into the glue or cement therein, as the assembly is advanced longitudinally. The glue is dried and cured by means of a resistance heater engaged in the grooves, outward of the cord and cement or glue therein. The heaters are arranged in fixed position and the assembled blocks are urged and moved by the heaters, as the assembly is advanced longitudinally.

In practice, the blocks B are established by inserting short pieces of lumber and scrap ends of lumber into a suitable fixture related to an electrically operated chopsaw. The fixture is preferably provided with a stop to control the length of the blocks and has a limit switch related to it, which switch controls the operation of the chopsaw. The chopsaw preferably has a block engaging member related to it, which member shifts the blocks from the fixture into a conveyor chute, on the return swing of the saw.

With a setup of the general character referred to above, it will be apparent that blocks B of uniform length, for establishing my new product, can be easily, conveniently and quickly established from any desired stock or supply of lumber and that they are deposited in a conveyor chute in a predetermined uniform manner, for subsequent assembly. I

Since the exact manner and means in and by which the blocks B are or can be established can vary widely without affecting the novelty of the present invention, I have chosen not to unduly burden this specification with detailed illustration and description of the steps and/or apparatus that might be taken and employed in carrying out this phase of manufacture.

In FIGURES 2 through 8 of the drawings, I have shown an apparatus for carrying out the process of manufacturing my new product P.

The apparatus is shown as including an elongate horizontally disposed way W having rear receiver and forward discharge ends 20 and 21. The way W is established of two elongate sections 22 having flat horizontally disposed base portions, laterally spaced longitudinally extending lower flanges depending from the side edges of the base portion and upwardly projecting, longitudinally extending, upper, side flanges 28, along the outer side edges of the base portion. The sections are arranged in side by side parallel relationship with their inner side edges in side by side relationship. The base portions of the channel sections establish fiat upwardly disposed, laterally spaced and longitudinally extending block supporting surfaces 23.

The rear, receiver end portion of the sections 22 are bent or turned upwardly to communicate and cooperate with the discharge end of a block supply chute, as will hereinafter be described.

The sections 22 are supported by transversely extending header portions of a plurality of longitudinally spaced horselike supports or standards 24. The lower edges of the lower flanges are slidably engaged on the header portions of said standards.

The sections 22 are provided with laterally outwardly projecting threaded shafts 25, which shafts overlie the standards 24 and project through apertured plates 26 on the standards. A pair of adjusting and locking nuts 27 are engaged on each shaft 25 to occur at the opposite sides of the plate 26 related thereto, which nuts are operable to shift the shafts and the sections laterally relative to the supports and to each other. With such a setup,

, the lateral spacing of the sections 22 can be advantageously adjusted to accommodate blocks of different length and to produce a product P of different width.

The upwardly projecting side flanges 28 at and along the outer edges of the sections 22, position and retain the blocks in lateral alignment, as they are advanced longitudinally of the construction.

The sections 22 can be integrally formed milled sections, or can be fabricated sections made up of suitable angle sections, T-sections or channel sections and plates, suitably welded together.

In practice, the flanges 28 are not coextensive with their related channel sections, but only extend along the inlet and outlet end portions of the channel and cooperate to define a gap or space 30 spaced between the ends of the sections to accommodate certain of the means provided to work upon the blocks, as will hereinafter be described.

The discharge end 20 of the way W opposes the discharge end 31 of a forwardly and downwardly inclined, upwardly opening U-shaped block delivery chute 32, down and through which a supply of cut or prepared blocks B is advanced. The chute 32 is slightly greater in lateral extent than the longitudinal extent of the blocks, to facilitate its function of receiving and conveying a supply of blocks and is slightly wider or greater in lateral extent than the lateral extent of the way W.

A pair of laterally spaced, opposing cone-shaped power driven rollers 35 are provided adjacent the junction between the chute 32 and the receiver end 20 of the ways, as illustrated in the drawings. The rollers 35 serve to engage and strip the blocks B advanced down the chute 32, from the chute, center the blocks relative to the way W and advance and urge the blocks into the way.

A stripper and keeper bar 36, having an upper rear end portion projecting between the rollers 35 and a lower forward portion overlying the rear portion of the way W is provided to strip the blocks from engagement with the rollers and to maintain the blocks engaged in the way.

Spaced forward of the rear, receiver end of the way W, I provide means for advancing the blocks B into tight, snug, sideby-side relationship. The block advancing means that 1 provide includes longitudinally spaced front and rear shafts 40 and 41 extending transversely above the way W, a pair of block engaging rollers 42 carried by the shaft 40 and a pair of block engaging rollers 43 carried by the shaft 41.

The means new under consideration further includes drive means for the shafts 40 and 41, which means includes manually adjustable clutch-type pulleys 44 at one end of each shaft, a prime mover 45 with a reduction gear 46 and a pair of drive pulley wheels 47. Drive belts 48 are engaged about and between the pulleys 44 and their related pulleys 47.

The drive means is such that it drives the roller 43 at a slightly greater rate than the rollers 42, whereby the rollers 43 serve to align the blocks with each other and eliminate any gaps that may occur therebetween. The rollers 42 thereafter act upon a continuous, uninterrupted surface established by the blocks and serve to drive the row of blocks forwardly.

In practice, when necessary or if desired, suitable support rollers 42 and 43 (shown in phantom lines) are or can be provided to support the work when it is directly below the rollers 42 and 43 and so that the work will not drag and be stopped on the way by excessive friction and as a result of the pressures exerted on the work by the rollers 42 and 43. The rollers 42' and 43' are rotatably supported by the lower flanges of the sections, below the base portions thereof and with their upper portions projecting upwardly through the suitable opening provided in the base portions, to be tangential with the surfaces 23 and of the sections 22.

Suitable pressure plates 49 are carried by the flange 28 of the Way W, at the forward discharge end thereof. The pressure plates 49 engage the product to create a drag or back pressure, against which the rollers 42 react and so that the rollers 42 urge the blocks into tight pressure engagement with each other.

The shafts 40 and 41 are rotatably supported by and extend between a pair of laterally spaced, upwardly projecting plates 50 fastened to the sections 22 of the way W by means of suitable screw fasteners 51. The screw fasteners 51 are engaged and extend through vertical slotlike openings 52 in the plates 50, which slots allow for vertical shifting and adjustment of the plates and the rollers 42 and 43, to cooperatively engage series of blocks of different vertical extent to thickness.

The motor 45 is mounted on a laterally outwardly projecting mounting flange 53 at the lower edge of one of the plates 50, as clearly illustrated in the drawings.

Spaced forward of the drive means, I provide a pair of flat, laterally spaced, vertically extending longitudinal mounting plates 60, which plates occur at the opposite sides of the way and within the laterally opening gaps or spaces 30 at the sides of the way and defined by the Tom and rear sections or portions of the flanges 28 of the sections 22.

The plates 60 are secured to the sections 22 of the way by means of screw fasteners 61 engaged through vertical slot-like openings 62 in the plates. With this relationship of parts it will be apparent that the plates can be shifted and adjusted vertically relative to each other, as desired, or as circumstances require.

Each mounting plate 60 is provided with an elongate,

horizontal and longitudinally extending slot 63, which slot occurs adjacent the related side surface Z of the row of blocks advanced longitudinally of the way and between the plates.

A saw means S is carried by each plate 60 to cut the groove G in the related side surface Z of the row of blocks. The saw means S is shown as including a horizontally disposed disc saw blade 63 carried by a shaft 65, which shaft is rotatably supported by a pair of vertically spaced mounting flanges 66 fixed to and projecting outwardly from the plate, above and below the opening or slot 63 therein. A portion of the blade 64 projects through the slot 63 and into the blocks B.

The shaft 65 is coupled with and driven by a motor M carried by an outwardly projecting mounting flange 67 at the lower edge of the plate 60.

With the means S set forth above, it will be apparent that as the row or supply of blocks B is advanced longitudinally in the way W, by or past the means S, thegrooves G in the side surfaces Z of the product are established.

Forward of the saw means S and carried by each of the plates 60 is a glue or cement applicator A.

The applicator A related to each plate 60 includes a block 70 fixed to the outer surface of the plate. The block 70 is provided with a laterally inwardly projecting longitudinal fin 71 which fin projects through the slot 63 in the plate and into the groove G just established by the saw means S.

The fin 71 occurs in the same horizontal plane as the saw blade and occurs immediately forward of the said saw blade and serves to guide and maintain the blocks B in proper aligned relationship.

The block 70 and fin 71 are provided with a fluid passage 74, the inlet end 75 of which opens laterally outward at the block and the discharge end 76 of which opens laterally inwardly and forwardly, at the inner and forwardmost portion of the fin and at the bottom of the groove G.

A supply hose 77 is connected with the inlet 75 of the passage and extends to a suitable pressure supply of liquid glue, or cement.

With the glue apparatus A that I provide, it will be apparent that a continuous uninterrupted supply of glue is deposited in the bottom of the grooves G as the work is advanced longitudinally through the way W.

Forward of the means A and carried by each plate 60 is a means for engaging the strings or cord-s C and arranging the cords in the grooves G. This means is shown as including :a flat, horizontally disposed feed disc or wheel 80 having a radially outwardly opening concave edge 81 to cooperatively engage a cord C. The disc is rotatably carried by a shaft 82, which shaft is carried by a pair of vertically spaced mounting flanges 83 fixed to the plate 60, above and below the forward end of the slot 63 therein, to project laterally outwardly therefrom.

A portion of the disc 80 projects through the slot 63 and into the groove G related thereto.

A bolt or supply 85 of string or cord C is carried by the plate flange 64. The cord extends upwardly from 1e supply 85 and over a suitable drag means D carried y the plate 60 and located forward of the disc. The rd extends rearwardly from the means D and is enaged about the disc to extend laterally inwardl and orwardly thereabout.

The disc urges the cord C, engaged about it, into presure engagement in the groove G and into engagement J'ith the glue or cement deposited in the groove by the means The forward end of the cord is suitably fixed to the ojrwardmost or first block B so that as the product is tdv'anced longitudinally through the apparatus, the cord 5 eifectively towed from the supply 85, about the means 5 and about the disc 80 in such a manner as to tension he cord and to position and deposit it in the groove.

The means D can be of any suitable design. For eximple, the said means can include a pair of axially aligned, )ppositely disposed friction cones around and between which the cord is engaged.

Finally, the apparatus includes a resistance heater H related to each side of the apparatus, which heaters are adapted to enter and extend longitudinally of the grooves 3, after the cords C are engaged therein. The heaters serve to heat and rapidly dry or cure the glue, as the product is advanced from the discharge end of the apparatus.

In the case illustrated, the heaters H are simple, elongate cartridge type resistance heaters. Each heater has an outer end mounted on a flange 90 at the exterior of the forward portion of the way flange 28 and has a laterally and longitudinally forwardly extending central and inner portion or portions which project through an opening 91 in the flange 28 and thence longitudinally forwardly in the groove G related thereto.

From the foregoing, it will be apparent that the glue can be heated and set very rapidly and before the finished product leaves the discharge end of the apparatus.

A suitable conveyor 95 can be provided at or adjacent the discharge end of the way W to receive and support the finished product issuing from the apparatus.

Having described only a typical preferred form and application of my invention, I do not wish to be limited to the specific details herein set forth, but wish to reserve to myself any modifications and/or variations that may appear to those skilled in the art and which fall within the scope of the following claims.

Having described by invention I claim:

1. The method of making an elongate fabricated wood board, rectangular in cross section and having laterally disposed end grain throughout its longitudinal extent including, arranging a plurality of wood blocks in side by side relationship with the grain of the wood thereof extending transverse the longitudinal axis of the assembly of blocks and disposed outwardly from two opposite sides of the assembly of blocks, next establishing an elongate uninterrupted outwardly opening groove in the other two opposite sides of the assembly of blocks and then engaging an elongate cord press fitted in each groove in fixed relationship with each block to extend between and hold the blocks in assembled relationship.

2. The method of making an elongate fabricated wood board, rectangular in cross section and having laterally disposed end grain throughout its longitudinal extend including, arranging a plurality of wood blocks in side by side relationship with the grain of the wood thereof extending transverse the longitudinal axis of the assembled blocks and disposed towards two opposite sides of the assembly of blocks, next establishing an elongate uninterrupted outwardly opening groove in the other two opposite sides of the assembly of blocks, next depositing a continuous body of glue in the groove and finally engaging an elongate cord in each groove and into contact with the glue to be secured in fixed relationship with each block and to extend between and hold the blocks in assembled relationship.

3. The method of making an elongate fabricated wood board, rectangular in cross section and having laterally disposed end grain throughout its longitudinal extent including, continuously arranging a plurality of wood blocks in side by side relationship with the grain of the wood thereof extending transverse the longitudinal axis of the assembly of blocks and disposed toward two opposite sides of the assembly of blocks and continuously advancing the assembly of blocks longitudinally as the blocks are progressively assembled, simultaneously and continuously cutting a longitudinal groove in the other two opposite sides of the assembly of blocks as the assembly is established and advanced longitudinally, depositing a continuous body of glue in the grooves immediately following the establishment thereof and as the assembly is advanced, and simultaneously and continuously arranging an elongate cord, under tension, in each groove and in contact with the glue therein as the assembly is advanced to be glued in fixed relationship with each block and to extend between and hold adjacent blocks in fixed relationship.

4. The method of making an elongate fabricated wood board, rectangular in cross section and having laterally disposed end grain throughout its longitudinal extent including, continuously arranging a plurality of wood blocks in side by side relationship with the grain of the wood thereof extending transverse the longitudinal axis of the assembly of blocks and continuously advancing the assembly of blocks longitudinally as the blocks are progressively assembled, simultaneously and continuously cutting a longitudinal groove in opposite sides of the assembly of blocks as the assembly is established and advanced longitudinally, depositing a continuous body of glue in the grooves immediately following the establishment thereof and as the assembly is advanced, and simultaneously and continuously arranging an elongate cord, under tension, in each groove and in contact with the glue therein as the assembly is advanced to be glued in fixed relationship with each block and to extend between and hold adjacent blocks in fixed relationship, and finally, heating the grooves, cords and glue to progressively and continuously heat and set the glue as the assembly is advanced longitudinally.

References Cited by the Examiner UNITED STATES PATENTS 392,809 11/1888 Kelley 144--316 2,713,380 7/1955 Baumann 144-318 2,961,021 11/1960 Tibbals 144--318 FOREIGN PATENTS 953,681 10/1947 France.

508,728 7/1939 Great Britain.

WILLIAM W. DYER, JR., Primary Examiner.

R. I. ZLOTNIK, Assistant Examiner. 

1. THE METHOD OF MAKING AN ELONGATE FABRICATED WOOD BOARD, RECTANGULAR IN CROSS SECTION AND HAVING LATERALLY DISPOSED END GRAIN THROUGHOUT ITS LONGTUDINAL EXTENT INCLUDING, ARRANGING A PLURALITY OF WOOD BLOCKS IN SIDE BY SIDE RELATIONSHIP WITH THE GRAIN OF THE WOOD THEREOF EXTENDING TRANSVERSE THE LONGITUDINAL AXIS OF THE ASSEMBLY OF BLOCKS AND DISPOSED OUTWARDLY FROM TWO OPPOSITE SIDES OF THE ASSEMBLY OF BLOCKS, NEXT ESTABLISHING AN ELONGATE UNINTERRUPTED OUTWARDLY OPENING GROOVE IN THE OTHER TWO OPPOSITE SIDES OF THE ASSEMBLY OF BLOCKS AND THEN ENGAGING AN ELONGATE CORD PRESS FITTED IN EACH GROOVE IN FIXED RELATIONSHIP WITH EACH BLOCK TO EXTEND BETWEEN AND HOLD THE BLOCKS IN ASSEMBLED RELATIONSHIP. 